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Apparently the electromagnetic clutch is engaging in the transfer case during normal driving conditions and its making a bad noise. I removed fuses 17 & 18 and the noise stopped. Is there any fix for this problem? Thanx, fitty
I'm too lazy to search back through your old posts to see what year you have and what else you have to report about your problem. Have you recently got (any) new tires or had any brake work done?
rrgone, I appreciate your help. You helped me before and thanks. Anyways it an 03 Explorer EB 4wd tc 4.0. I think I rotated the tires maybe 3-4 mos ago. I don't drive it that much but it seems everytime I do the noise will happen at least 4-5 times while driving and it only does it when I let off the gas (or I only hear it then). If you change air pressure, brakes or rotate your tires , the effect it has on the TC system is annoying. Is there a way to make it stop? Again thanks for your help. fitty
The wheel speed sensors measure speed of the front wheels and real differential. They talk to the ABS module which talks to the 4X4 control module. If the ABS module detects a wheel turning faster than the others it tells the 4X4CM which interprets this as wheel slippage. The 4X4CM then engages the electromagnetic clutch in the transfer case. The front wheel speed sensors can get damaged during brake work or replacing bearings/hubs. Also, even a small difference in tire tread can be reported by the wheel speed sensors as slippage.
Anyway, unless you have reason to think a wheel speed sensor is damaged I suggest you try rotating one rear tire with one front tire. Replace the fuses and see if that changes anything. Let us know.
I have a '97 with a similar problem but as far as I can tell the sensors are in the transfer case. Am I wrong and they are also on the wheels on the '97? I read that there is also a relay in there somewhere but I don't know where as yet. I have a leak at the rear output shaft so tomorrow I'm planning on replacing the seal and fluid and see if that helps.
I have new Michelin LTXs that have been rotated and rebalanced and the problem was still the same.
For OP: I did the "brown wire modification" so I can switch back to 4WD when needed. I don't know if it also applies to yours or if it's limited to only the '95-'97 Explorers.